George s



(No Model.) I

G. S; MAYHEW.

ARTIFICIAL LUMBER AND GOMPOS I 'IION MATERIAL.

No.51'7,82 2. Patented Apr.3,1894,

70/14:. Wanda 471.421.

' 1' I hvenjfozi I B %ZQM I wiiorheyof UNITED STATES GEORGE S. MAYHEW,

PATENT OFFICE.

OF MINNEAPOLIS, MINNESOTA, ASSIGNOR TO CHARLES AXIL SMITH, OF SAMEPLACE.

ARTIFICIAL LUMBER OR COMPOSITION MATERVIAL.

SPECIFICATION forming part of Letters Patent No. 517,822,dated April 3,

Application filed May 2, 1893. SerialNo. 472.798- (No model.)

T0 on whom it may concern:

Be it known that I, GEORGE S. MAYHEW, o

' Minneapolis, in the county of Hennepin and State of Minnesota, haveinvented a certain new and Improved Artificial Lumber or GompositionMaterial, of which the following is a specification.

My invention relates to a material or lumber composed of layers of paperand wood each retainingits identity and secured together in such amanner as to form a smooth surfaced and even board of any desiredthickness and of extraordinary strength, solidity and inflexibility andpossessing atthe same time qualities which render it durable in nearlyall uses and climates.

The object of-my invention is to provide a composition material made upin the form of large boards and which will be strong and durable, andnot shrink, swell, or warp, andwhich will above all things possess asmooth even and unbroken surface adapting the same for use in the finestinterior finish-of houses as well as adapting it for employment incabinet work, various lines of manufacture and many of the less,exacting arts. p To this end my invention consists in the combination,with a body or core made up of a series of wide but thin wooden boardsor sheets laid edge to edge and the grain thereof having a commondirection, of a series of thinner but preferably wider sheets or veneersof wood laid with their grain extending transversely to that of the coresheets, and two thick sheets of paper arranged uponopposite sides of thecomplete core thus formed, and the whole being firmly secured togetherby a suitable quick drying adhesive material to form a singlehomogeneous mass having the form of a thin, wide, and long board.

My invention consists further in carryingwebs for the adhesive materialand permanently'arranged between the inner and outer parts or courses ofwood. v

My invention consists further in particular construction for the severalparts and in various combinations all as hereinafter described andparticularly pointed out in the claims.-

The invention will be more readily under-- stood by reference to-the'acco mpanyingdrawings, forming a part of this specification, and inwhich-- Figure 1 is a perspective view showing a I piece of compositionmaterial embodying my invention. Figs. 2, 3, and 4, are enlarged viewsof several of the many forms of serrated edges which I employ for partsof my material.

' As shown in the drawings, my composition material or composite boardis made up of two sheets 3 and 4 of 'thick heavy straw or pulp board,between which are secured, by a suitable adhesive material, a number. ofwooden parts composinga strong and inflexible core, which is givensmooth surfaces by the thick paper facings. The inner parts 2 of thecore consist in a series of wide butthin sheets of wood, the grain ofwhich has a common direction transverseto the length of the long sheets3 and 4. These parts 2 may extend clear across the wide paper sheets ora portion thereof may be of less length and be pieced out by shorter andsmaller parts 2', as shown in Fig. 1. With this construction the longwooden sheets 2 have their ends lapped by one another so that the jointsbetween "the long and the short pieces do not form themselves into acontinuous line throughout the length of the large boards. The innersheets 2 are provided in opposite sides with a series of closelyarranged rows of deep indentations 5, which extend nearly through theboard but not clear through the same, leav- 1 ing small solid partsbetween the several strips into which each wide sheet is so nearlyseparated. These indentations may partake of the form of deep groovesinstead of a series of small indentations but I prefer the latter.Either form separates the wide sheet or sheets 2 into alarge number ofsmall parts running lengthwise with the grain and thereby preventingtransverse shrinkage or warping, while the solid portions between theseveral longitudinal parts serve to lock the same to one another andprevent one part swelling or shrinking and moving with respect to theother. The surfaces of this inner core, having the transverse grain, arecoveredby thin webs 6 of paper or cloth and of just sufficient strengthto carry the Weight caused by a thorough coating of both its sides witha quick setting adhesive material. Byapplying the adhesive material inthis way the body thereof is kept too small to permeate the indentations5 to prevent their performing theproper function. The cracks between thewide sheets 2 are preferably filled with the adhesive material tosecuresaid parts to-.

serrated being here intended. to mean any form of tongued and notchededge. The serintededgesof the several veneers. fit into one? anotherrespectively and thetonguesof on 9; completely interlock with those oftheadj oining-veneeithereby preventing movement: of

either veneer withrespeet to the-,other, which;

movement might result in warping the compositeiboard of which they formapart. The thick sheets2 aresecured upon the smooth surfaces made bythewide and: thin veneers,

the same. kind. of adhesive material, which; is employed upon the Websbeing preferably sed bet een the inners-ides ot the long papen Sheets-3nd ts-and the veneers.

In, the drawings thezthickness-of thecomposite bQard formed of all theabove described} parts is considerably exaggerated, while the lengthandwidth of the parts thereof are shown very much smaller thaniupractice, asttheipants Zane oftenfromtwelvetoi fifteen inches in. Wid h;and from two to sixf'eetin;

length and. the veneers 7 are preferably at 1 least twelve inches inwidth'and of' greater length than-width. The serrated edge mayhavetheform of a V-tongue-and a notch; or anahnuptor square end with'inclined sidesias shown in Fig. 2.,

Laplace of the form. shown in Fig, 21 may use-that. shown in Fig;3-w-here all of the anglee of the tongues and notches-are inclined withrespect to the. original streightedge of thevcneer or' widesheet. Whilein-Fig t cunvedi tongues and. notches are shown as equally desirable Theparts of theboard, after being assembled,.and connected by adhesivematerial, are subjected to a, heavy .pressurewhich disseminates thequick. setting adhesive; material and forces the same into thercraeksextending: through fromzsheet to-sheetof the. enveloping paper as.before iflifid; but. not into the indentations. The serrated ontlines ofthe thin veneers furnish such. an extendedarea or passage. for theadhesivematerial that the sameis spread over erylarge surfaceandprevented fro m formingridges, which, when hardenedmightform ridges.beneaththe surfacesheets3 and iand mar thesmooth appearanceof thesame.By the; useof thelpeculiarlyformed veneers, however, in the shapedescribed this difficulty is overcome and a perfectly smooth surfaceobtained upon each side off thecomposite board.

The wooden parts before being used are preferably dried and particularlythe veneers, which are usually heated to sucha high defg-reeastod-cstroythe life of the wood. After the composiitelhoard ispressed'it is dried in a suitable kiln. It is obvious that the crossedgrains of theparts of the wooden core and the equal strength thereof atall points absolutely prevent the warping or bulging of the compositeboard due to shrinking or warping of the parts thereofl The board thusformed afiter bei ng dried is extremely strong and inflexible thoughcapable of being easily worked by ordinary earpenteflstoolsand has suchaquality of denseneseas; to bola; very poor conductor of soiund cxcept;where specially designed and subjected. 12.09am extraordin-arilyheawypnessune. Aninfierionquality of material may he. mad-elwith atconecomposed of thin wooden strips arrangcd in thnee courses, tzhe grainof theicuiter courses extendy ingin an oppositedirectiontothatofthe-middie; course, oronei course of the thinisthips-(or gone course ofthe wideveneerslin the board 'descri.b.ed); may be. omitted. Thecomposite board. so: constructed however isfar more apt towarp. than theboard first: described and 1 though the-lattercostssomew-hatmoreih muchprefer its use.

By the employment of fire or water proof smatenialzon both in theconstrnetioniof my hoard, making-- cit-hen the adhesive: material, onthepaper board used fire: or water proctor hoth, theboardlsoconstitutedmay be adapted to resist the actionof fircior water.

Having thus. described my invention, I claim as. new and desi re to:secnne Letters Patent--- 1. In an artificial luimben or compositionmaterial awooden corelcomposediot threethin i layersof wood each made upof a SBIlBSEOfi thin sheets or stripsandxthe grain of theouterlayershaving acommon direction transversoto that of themiddleslayer, in. combinationiwith .thickpaper. or pulpboar-d facingsfor said ore and an inter-posed adhesive'material or GGIIlBUl?betweenand securing allof saidparts firmly together toform athinhutrinflexible hoard, substantially asdescribed;

2. The combination ina; composition material. of two-thick. sheets ofheavy paper or I pulp board-witha core anrangedbetween said sheets ofpaper and composed of. a layer of 3 wide but thinr sheetstof. wood;andgtwo-layers arrangeduponopposite sidesthereofandcomposedof thin;wideiveneersearranged transversely with respectto said sheets'ofwoodand-aan interposed adhesivematerialsecuring gallrof said partsfirmly togethcr, substantially asdescribed. 1

. 3. The combination, in an artificiullumber or composition material, ofseries of thin wide a wooden i sheets, with a. thin"cement-carrying-webs arranged upon opposite sides of said series orlayer, and thin and wide veneers laid pose specified.

.4. The combination, in an artificial lumber or composition material, ofa series or layer of thin wide wooden sheets, with thincementcarrying-webs arranged upon opposite sides of said series orlayer, and thin and wide veneers laid upon opposite sides thereof withtheir grain running across that of the said wooden sheets, and thickpaper orpulp board facings secured upon said veneers by a suitableadhesive material or cement, substantially as described. p

5. The combination,in an artificial lumber or composition material, of aseries of thin wide sheets of wood arranged edge to edge and provided intheir opposite sides with a series of rows of indentations, with aseries of thin wide wood veneers arranged upon opposite sides of saidthin sheets and secured thereto by an adhesive material,.said veneersbeing arranged with their grain crossing that of said sheets,substantially as described.

6. The combination,in an artificial lumber orcomposition material, of aseries of thin sheets of wood arranged edge to edge and having theirsides provided with a series of rows of indentations, thin wide woodveneers arranged upon opposite sides of said thin sheets of wood, thicksheets of paper or pulp board inclosing said veneers and an adhesivematerial interposed between said parts to secure the same firmly andinflexibly together, substantially as described.

7. The combination, in an artificial lumber or composition material, ofthe thin wide sheets of wood arranged edge to edge and having both sidesprovided with a series of rows of indentations extending with the grainof the wood, with a course of thin woodveneers laid cross-grained tosaid sheets of wood; with sheets of paper secured upon opposite sides ofthe wooden core so formed by a suitable adhesive material, substantiallyas described.

8. The combination, in an artificial lumber or composition material, ofthe thin wooden sheets arranged in a thin layer with the carrying websfor the adhesive material and whereby the same is applied, thin woodveneers having serrated and interlocking edges and securedby theadhesive material upon saidwebs, the grain of the wood veneers extendingin an opposite direction to that of the wooden sheets, substantially asdescribed.

9. The combination, in an artificial lumber or composition material ofthe, thin wooden sheets arranged in a thin layer with two layersarranged upon opposite sides thereof and each composed of a series ofthin wood veneers having serrated and interlocking edges, and the thickpaper or pulp board facings secured upon said veneers and all partsbeing firmly secured together by a suitable adhesive material,substantially as described.

10. The combination, in an artificial lumher or composition material, ofV the thin wooden sheets, with the carrying webs forthe adhesivematerial and whereby the same is applied, thin wood veneers havingserrated and interlocking edges and secured by the. adhesive materialupon said webs, the grain of the wood veneers extending in an oppositedirection to'that of the wooden sheets, and thick facings of artificialmaterial secured upon said veneers by adhesive material, substantiallyas described.

11. The combination, in an artificial material or composition material,of the thin wooden sheets arranged edge to edge with carrying webs foradhesive material applied to opposite sides of said wooden sheets, thinwooden veneers arranged across grain to and secured upon the same, thickpaper sheets secured upon said veneers, said wooden sheets provided withthe closely arranged indentations in opposite sides, said veneers havingserrated interlocking edges, and the whole secured together by anadhesive material and subjected to a heavy pressure and dried,substantially as described.

In testimony whereof witness my hand this 22d day of April, A. D. 1893.

' GEORGE S. MAYHEW.

In presence of- O. G. HAWLEY, A. R. ROGERS.

